Building The ANH 5'Millennium Falcon

Discussion in 'Studio Scale Models' started by eagle1, Aug 5, 2012.

  1. eagle1

    eagle1 Sr Member RPF PREMIUM MEMBER

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    The modern koolshade is I think 17 louvres per inch as opposed to 21 for the vintage yes?. Do you see much of a difference?. I have the vintage shade, stuffs like gold these days to find. I did see a guy in Spain I think it was, selling a big vintage sheet on Facebook, think that got snapped up quick!.

    - - - Updated - - -

    Cheers Mike, c'mon man you gotta start your build, join the fun...or is it madness haha.
     
  2. greeble_gremlin

    greeble_gremlin Well-Known Member RPF PREMIUM MEMBER

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    Hey Stu,

    Man you don't know how badly I want too start my bird!
    I've had all the kits stockpiled for a while now, (with the exception; finally added the 1/25 Centurion)
    I'm finally ready to post about the 1/12 X-Wing (look for the thread soon ) also some 1/18 scale X-wing and new 1/24 Laser cut wings kit.
    As soon as that project out the door, I can turn my attention to the Falcon.
    1-12 R2 Strip Parts WIP_1sm.jpg Wing Root WIP_1sm.jpg

    I should have a big pressure pot by then... a must for good castings, which is a must for building the Falcon.

    Stu I am curious about your solution for the "curved" "hamburger bun" part of the hull.
    What did you come up with?
     
  3. greeble_gremlin

    greeble_gremlin Well-Known Member RPF PREMIUM MEMBER

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    The 5'-Footer project is so big... I can't get my head around it all at once. I need to do like you, and just focus on one section at a time.
    I would like to start with the gun turrets, - that would get me "stoked" on this build.

    Your Quad Laser cannons look great by the way!


    I also have not contributed to the Falcon builders community as much as i would like too.
    I hope I can give the Falcon builders an acceptable solution to the Kool-Shade issue.

    I did make these last February. The test prints worked out great ! ...more durable than I had hoped.
    As these have a pass-thru grill they are not cast able but will need to be 3D printed. ..still cheaper than real Kool-Shade.
    Engine Grill Fit.jpg VKS Ring_1.jpg VKS Ring_2.jpg
    Normally the Virtual Kool shade is too "delicate" as an actual "grill" ( the 3D printed material does not have the tensile strength of real metal/brass)
    ..But because of the ring/frame there is added strength. I was also able to add support from the back side of the grill, which remains hidden quite nicely
    These grills are of course too "perfect". -- I need to go in and bend up the louvers, which won't take too long, got to make 6 unique rings though (each is bent-up a bit different)

    I will also make some VKS for the sections along the top of the docking bay ridges.
    Those will have "backing" so they will be castable and much cheaper to reproduce than 3D Printing each one.
    I also did some experimenting with the section of Kool Shade on the Cockpit Tunnel.
    I think I can provide a convincing "castable" version of the VKS for this section which will also bring down the cost.
    There is the issue of the diameter of the Cockpit Tunnel, some folks are building their's at different diameters.

    VKS Ring_3.jpg VKS Ring_4.jpg Weave_CloseUP.jpg

    I'm not sure if there would be much interest for an affordable Kool-Shade substitute.
    The modern stuff might look just fine on the Falcon (without the 21 louvers per inch next too it, to compare too)
     
    Last edited: Aug 12, 2017
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  4. eagle1

    eagle1 Sr Member RPF PREMIUM MEMBER

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    Heya Mike,

    Well hurry up, you know you want one bad haha.
    X-Wing parts looking great, boy that project has gone on for quite a few years now huh, my abandoned effort back when is long forgotten...gulp!.

    I will post on the hull build later on when I have something to show & can post up progress pics describi g the process. I have it worked out, just getting my mandibles done for now.

    I think your workings on the koolshade will be invaluable to other builders to have the opportunity to have the real deal alternative. This stuff is fast disappearing, if any left at all now...who knows. The newer shade is nice but the louvre count is noticeable.

    Stu
     
  5. eagle1

    eagle1 Sr Member RPF PREMIUM MEMBER

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    More progress. Starboard side mandible nearing completion. A few donors yet to place in the pit wells & chipping & adding pipework to do. But starting on the port side mandible in the meantime.
    This thing is wonky, the actual miniature I mean. To replicate all those intricacies is all part of the building process, but it slows you down somewhat to achieve a good replica.
    I will have acrylic beams that slide through the mandibles from the core that will provide alignment & strength. Not sure yet if I will have the mandibles as removable or glue them in place.

    Stu
     

    Attached Files:

  6. bigpetr

    bigpetr Member

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    Beautiful. Keep pictures coming please (y))
     
  7. Moska

    Moska Well-Known Member

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    (y)thumbsup :love (y)thumbsup
     
  8. joberg

    joberg Master Member

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    Huge beast for sure and lookin' Ace!!
     
  9. TazMan2000

    TazMan2000 Sr Member

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    Size does matter. Great build. Glad you're still on it.

    TazMan2000
     
  10. eagle1

    eagle1 Sr Member RPF PREMIUM MEMBER

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    Cheers guys, yes for sure pics will keep on coming. I'll post up some progress of the port mandible in construction as well as the pits over the weekend.

    Stu
     
  11. eagle1

    eagle1 Sr Member RPF PREMIUM MEMBER

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    Some more progress. The large underside pits worked on. The McLaren pit has a only a few parts to add & the Tiger ll/Chieftain pit a number of parts to add & a few more pipes.
    Mandibles still require the relief chipping & still a few more parts to add in various pits. Kits acquired as I go along, which seems a never ending cycle haha.
    Masters for the sidewalls & jawbox plates are nearing completion & casts will be done, as per ILM.
     

    Attached Files:

  12. satazius

    satazius Well-Known Member RPF PREMIUM MEMBER

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    Wow. Amazing to see this come together. Thanks so much for sharing these in-progress pics!
     
  13. t2sides

    t2sides Sr Member

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    EXCELLENT Work Stu!!! Pro work all the way!!! Your attention to detail, and clean lines and applications are just amazing! You are absolutely nailing the details and putting this together so nicely! Keep up the great work, and the excellent progress pics!!! So cool to see another 5 Footer coming on line!!
    Sean
     
  14. seven

    seven Sr Member

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    Is the depth of the mandible pits all different too?
     
  15. eagle1

    eagle1 Sr Member RPF PREMIUM MEMBER

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    Yes. When building the pits I had to keep two things in mind...depth & width. Certain kit parts gave the depth indicator as to a particular pits depth. Of course this determines the pit that sits immediately underneath as well, but when you have one depth sorted the other kind of falls into place & can be doubled checked to make sure there is enough clearance for both in the internal mandible space. It's tight in there for sure & the odd kit part was trimmed, say a landing gear, to fit the pit sidewall. I built my pits separately & fixed in place later, keeping in mind the correct orientation. ILM would have detailed the pits out in situ, but seemed easier for me to do separately & work out diameters & depths.


    Stu
     
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  16. eagle1

    eagle1 Sr Member RPF PREMIUM MEMBER

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    Thought I'd post some progress on my hull dome work.
    I realised early on & couldn't find a place in New Zealand anyway to blow mold one piece domes, that really, there is no point to full domes, why wouldn't a half dome or even a quarter dome section work!. So that's what I have done, built an oversize quarter section form or tool, to have the domes vacformed in 4.75mm ABS. The tool is oversized to allow good pulls & trimming when placed on my core. The tool was all CNC'd MDF. Just finishing up the skinning now, which is 3mm MDF. All this will be sanded smooth & filled if needed & sanded again & sealed. Then it will be down to the plastic formers for vacforming. 10 pulls will be needed for 1 Falcon, 8 for the 2 domes,1 for the engine deck & the last for the engine petal strips & maybe another as a spare.

    20180810_143158.jpg

    20180810_143141.jpg

    20180820_153503.jpg
     
    Last edited: Sep 11, 2018
  17. kokkari

    kokkari Sr Member

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    That is simply incredible!

    Sent from my SM-G955U using Tapatalk
     
  18. eagle1

    eagle1 Sr Member RPF PREMIUM MEMBER

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    Thank you sir!. The tool is pretty heavy as you can imagine, but at least it won't move on the vacform bed haha.
     
  19. Flixen

    Flixen Active Member

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    Fantastic idea!
    Thanks for sharing.
     
  20. ModelBuilder

    ModelBuilder New Member

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    Awesome job with this Stu!
     
  21. eagle1

    eagle1 Sr Member RPF PREMIUM MEMBER

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    Cheers guys!.

    I should point out that I had originally thought of doing the domes as a series of ribs & skinned in styrene with the old pizza wedge method, which works, but decided this would create a headache to get the various pits in situ, especially the big underside pits!. Having the domes as shells means the area underneath is mostly hollow, a part from a rib at the 12, 3, 6 & 9 positions which hold up the quarter domes. I'll decide at the time if further ribs are required, maybe an overkill, but only when the pits are positioned.
     
  22. joberg

    joberg Master Member

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    You're right about the rig: won't move when that plastic sheet will be sucked down to the table:D Great buck btw:thumbsup
     
  23. faustus100

    faustus100 Well-Known Member

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    I read your analysis of the access pits,i also did mine separately and joined them later.
    [​IMG]
    A few examples
    Worked out well,as they all are practically different depths.
    [​IMG]
     
    Last edited: Sep 10, 2018
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  24. faustus100

    faustus100 Well-Known Member

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    That rig is a great idea!! Cant wait to see the pulls! Your bird is coming out exceptionally!BTW I was only able to score the newer cool shade on a trade. Were you able to find the old stuff at all.
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    Newer shade certainly doesn't have the same 'depth' as the old.
    Think it's passable on smaller areas,not sure.
    [​IMG]
     
    Last edited: Sep 10, 2018
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  25. eagle1

    eagle1 Sr Member RPF PREMIUM MEMBER

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    Yeah it just made more sense to construct the mandible pits separately & glue in situ before closing up. I'm sure ILM had the blank pits in place on the original & then detailed them out, but to try & replicate what they did as best as possible, then separately was best practice. Worked out great.

    Yes I have the vintage Koolshade, I managed to get a decent sheet a few years back.

    Stay tuned for dome pull pics!.

    Stu
     
  26. faustus100

    faustus100 Well-Known Member

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    Can't wait! What's the diameter of your dome going to be?
     
    Last edited: Sep 11, 2018
  27. eagle1

    eagle1 Sr Member RPF PREMIUM MEMBER

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    Finally got my domes done!.

    Dropbox - 2018-11-02 14.04.31.mp4

    Above is a wee video of one being formed.
    Dome quarters are oversized to allow trimming to fit precisely. They will be screwed & glued into the core bulkheads.
    So glad I went the way of making these as vacformed shells, no problem now of fitting all the various hull pits, especially the 2 big underside pits, those would have been a nightmare to fit in if a rib construction was used!.

    Stu 20181109_132002.jpg 2018-11-02 14.31.58.jpg 2018-11-02 14.32.06.jpg 2018-11-02 15.20.58.jpg
     
  28. ModelBuilder

    ModelBuilder New Member

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    Stu, absolutely amazing job with this! They look awesome!
     
  29. greeble_gremlin

    greeble_gremlin Well-Known Member RPF PREMIUM MEMBER

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    Very Nice Stu!
     
  30. eagle1

    eagle1 Sr Member RPF PREMIUM MEMBER

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    Here is my 'kit' I designed for my hull or 'core' & delivered just before Christmas. All parts are CNC'd from MDF & also had an armature welded up. So over the holiday break I began assembly & am pretty darn happy how it all fits & is taking shape. I applied a light coat of PVA to the sidewalls to seal the MDF for the styrene to attach to securely with CA. It's really hot here last few weeks, so drying time & bonds are real quick!. Next up this week are fitting the ABS dome sections, I say fitting, but won't secure them down until pit positions are finalized & positioned.
     

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  31. motionminded

    motionminded Member RPF PREMIUM MEMBER

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    Looking solid Stu!
     
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  32. ModelBuilder

    ModelBuilder New Member

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    Looks Awesome Stu!!!!
     
    eagle1 likes this.

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